Impingement panel support structure and method of manufacture

ABSTRACT

An integrated combustor nozzle includes a combustion liner that extends between an inner liner segment and an outer liner segment along a radial direction. The combustion liner including a forward end portion, an aft end portion, a first side wall, and a second side wall. An impingement panel having an impingement plate disposed along an exterior surface of one of the inner liner segment or the outer liner segment. The impingement plate defines a plurality of impingement apertures that direct coolant in discrete jets towards the exterior surface of the inner liner segment or the outer liner segment. The impingement panel includes an inlet portion that extends from the impingement plate to a collection duct. The impingement panel further includes a plurality of supports spaced apart from one another. The plurality of supports extend between, and are coupled to, the inlet portion, the collection duct, and the impingement plate

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

This invention was made with Government support under Contract No.DE-FE0023965 awarded by the United States Department of Energy. TheGovernment has certain rights in this invention.

FIELD

The present disclosure relates generally to an integrated combustionnozzle for a gas turbine engine. More specifically, this disclosurerelates to various cooling components for an integrated combustionnozzle.

BACKGROUND

Turbomachines are utilized in a variety of industries and applicationsfor energy transfer purposes. For example, a gas turbine enginegenerally includes a compressor section, a combustion section, a turbinesection, and an exhaust section. The compressor section progressivelyincreases the pressure of a working fluid entering the gas turbineengine and supplies this compressed working fluid to the combustionsection. The compressed working fluid and a fuel (e.g., natural gas) mixwithin the combustion section and burn in a combustion chamber togenerate high pressure and high temperature combustion gases. Thecombustion gases flow from the combustion section into the turbinesection where they expand to produce work. For example, expansion of thecombustion gases in the turbine section may rotate a rotor shaftconnected, e.g., to a generator to produce electricity. The combustiongases then exit the gas turbine via the exhaust section.

In many turbomachine combustors, combustion gases are routed towards aninlet of a turbine section of the gas turbine through a hot gas paththat is at least partially defined by a combustion liner that extendsdownstream from a fuel nozzle and terminates at the inlet to the turbinesection. Accordingly, high combustion gas temperatures within theturbine section generally corresponds to greater thermal and kineticenergy transfer between the combustion gases and the turbine, therebyenhancing overall power output of the turbomachine. However, the highcombustion gas temperatures may lead to erosion, creep, and/or low cyclefatigue to the various components of the combustor, thereby limiting itsoverall durability.

Thus, it is necessary to cool the components of the combustor, which istypically achieved by routing a cooling medium, such as the compressedworking fluid from the compressor section, to various portions of thecombustion liner. However, utilizing a large portion of compressedworking fluid from the compressor section may negatively impact theoverall operating efficiency of the turbomachine because it decreasesthe amount of working fluid that is utilized in the turbine section.Accordingly, an improved system for cooling a turbomachine combustor isdesired in the art. In particular, a system that efficiently utilizescompressed working fluid from the compressor would be useful.

BRIEF DESCRIPTION

Aspects and advantages of the assemblies and methods in accordance withthe present disclosure will be set forth in part in the followingdescription, or may be obvious from the description, or may be learnedthrough practice of the technology.

In accordance with one embodiment, an impingement panel is provided. Theimpingement panel configured to provide impingement cooling to anexterior surface. The impingement panel has an impingement platedisposed along the exterior surface. The impingement plate defines aplurality of impingement apertures that direct coolant in discrete jetstowards the exterior surface. The impingement panel includes an inletportion that extends from the impingement plate to a collection duct. Atleast one support coupled to the impingement plate and at least one ofthe inlet portion and the collection duct.

In accordance with another embodiment, an integrated combustor nozzle isprovided. The integrated combustor nozzle includes a combustion linerthat extends radially between an inner liner segment and an outer linersegment. The combustion liner including a forward end portion, an aftend portion, a first side wall, and a second side wall. The aft endportion of the combustion liner defines a turbine nozzle. The integratedcombustor nozzle further includes an impingement panel. The impingementpanel has an impingement plate disposed along an exterior surface of oneof the inner liner segment or the outer liner segment. The impingementplate defines a plurality of impingement apertures that direct coolantin discrete jets towards the exterior surface of the one of the innerliner segment or the outer liner segment. The impingement panel includesan inlet portion that extends from the impingement plate to a collectionduct. At least one support coupled to the impingement plate and at leastone of the inlet portion and the collection duct.

In accordance with yet another embodiment, a method for fabricating animpingement panel is provided. The method includes a step of irradiatinga layer of powder in a powder bed to form a fused region. The powder bedis disposed on a build plate. The method further includes a step ofproviding a subsequent layer of powder over the powder bed by passing arecoater arm over the powder bed from a first side of the powder bed.The method further includes repeating the irradiating and providingsteps until the impingement panel is formed on the build plate. Theimpingement panel includes an impingement plate that defines a pluralityof impingement apertures. The impingement panel further includes aninlet portion that extends from the impingement plate to a collectionduct. At least one support coupled to the impingement plate and at leastone of the inlet portion and the collection duct.

These and other features, aspects and advantages of the presentassemblies and methods will become better understood with reference tothe following description and appended claims. The accompanyingdrawings, which are incorporated in and constitute a part of thisspecification, illustrate embodiments of the technology and, togetherwith the description, serve to explain the principles of the technology.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present assemblies, including thebest mode of making and using the present systems and methods, directedto one of ordinary skill in the art, is set forth in the specification,which makes reference to the appended figures, in which:

FIG. 1 is a schematic illustration of a turbomachine, in accordance withembodiments of the present disclosure;

FIG. 2 is an upstream view of an exemplary combustion section of aturbomachine, in accordance with embodiments of the present disclosure;

FIG. 3 is a perspective view of an integrated combustor nozzle, asviewed from a first side, in accordance with embodiments of the presentdisclosure;

FIG. 4 is a perspective view of an integrated combustor nozzle, asviewed from a second side, in accordance with embodiments of the presentdisclosure;

FIG. 5 is a perspective view of an integrated combustor nozzle, which isshown having various cooling components exploded away, in accordancewith embodiments of the present disclosure;

FIG. 6 is a cross-sectional schematic view of an integrated combustornozzle from along a radial direction of the turbomachine, in accordancewith embodiments of the present disclosure;

FIG. 7 is an enlarged cross-sectional view of a portion of an outerliner segment of an integrated combustor nozzle, in accordance withembodiments of the present disclosure;

FIG. 8 is an enlarged cross-sectional view of a portion of an innerliner segment of an integrated combustor nozzle, in accordance withembodiments of the present disclosure;

FIG. 9 is a plan view from along the radial direction R of twoimpingement panels and a cooling insert, isolated from the othercomponents of the integrated combustor nozzle, in accordance withembodiments of the present disclosure;

FIG. 10 is a cross sectional view of a panel segment of an impingementpanel from along the axial direction A of the turbomachine, and inaccordance with embodiments of the present disclosure;

FIG. 11 is plan view of the panel segment shown in FIG. 10 from alongthe radial direction R of the turbomachine, in accordance withembodiments of the present disclosure;

FIG. 12 is a cross-sectional perspective view of a panel segment, inaccordance with embodiments of the present disclosure;

FIG. 13 is a plan view of a first end of the panel segment shown inFIGS. 10-12 from along a center axis, in accordance with embodiments ofthe present disclosure;

FIG. 14 is a plan view of a second end of the panel segment shown inFIGS. 10-12 from along a center axis, in accordance with embodiments ofthe present disclosure;

FIG. 15 is a schematic/block view of an additive manufacturing systemfor generating an object, in accordance with embodiments of the presentdisclosure;

FIG. 16 is a flow chart a method for fabricating an impingement panel,in accordance with embodiments of the present disclosure;

FIG. 17 is a perspective view of the impingement cooling apparatus,which is isolated from the integrated combustor nozzle and positioned ona build plate, and in which one of the impingement members in a row hasbeen cut away, in accordance with embodiments of the present disclosure;

FIG. 18 is an enlarged cross-sectional view of the integrated combustornozzle from along the radial direction R of the turbomachine, in whichthe impingement cooling apparatus is positioned within a cavity of theintegrated combustor nozzle, in accordance with embodiments of thepresent disclosure;

FIG. 19 is a cross-sectional view of a single impingement member, inaccordance with embodiments of the present disclosure;

FIG. 20 an enlarged cross-sectional view of an impingement member and aportion of two neighboring impingement members from along the radialdirection R of the turbomachine, in accordance with embodiments of thepresent disclosure;

FIG. 21 is an enlarged view of an impingement wall stand-off prior tothe removal of excess material, in accordance with embodiments of thepresent disclosure;

FIG. 22 is an enlarged view of an impingement wall stand-off after theremoval of excess material, in accordance with embodiments of thepresent disclosure;

FIG. 23 is a flow chart a method for fabricating an impingement coolingapparatus, in accordance with embodiments of the present disclosure;

FIG. 24 is a perspective view of a cooling insert, which is isolatedfrom the other components of the integrated combustor nozzle, inaccordance with embodiments of the present disclosure;

FIG. 25 is a cross-sectional view of a cooling insert from along theaxial direction A of the turbomachine, in accordance with embodiments ofthe present disclosure;

FIG. 26 is a cross-sectional view of a cooling insert from along theradial direction R of the turbomachine, in accordance with embodimentsof the present disclosure;

FIG. 27 is a cross-sectional view of a cooling insert from along thecircumferential direction C of the turbomachine, in accordance withembodiments of the present disclosure; and

FIG. 28 is an enlarged view of two oppositely disposed cooling inserts,in accordance with embodiments of the present disclosure.

DETAILED DESCRIPTION

Reference now will be made in detail to embodiments of the presentassemblies, one or more examples of which are illustrated in thedrawings. Each example is provided by way of explanation, rather thanlimitation of, the technology. In fact, it will be apparent to thoseskilled in the art that modifications and variations can be made in thepresent technology without departing from the scope or spirit of theclaimed technology. For instance, features illustrated or described aspart of one embodiment can be used with another embodiment to yield astill further embodiment. Thus, it is intended that the presentdisclosure covers such modifications and variations as come within thescope of the appended claims and their equivalents.

The detailed description uses numerical and letter designations to referto features in the drawings. Like or similar designations in thedrawings and description have been used to refer to like or similarparts of the invention. As used herein, the terms “first,” “second,” and“third” may be used interchangeably to distinguish one component fromanother and are not intended to signify location or importance of theindividual components.

As used herein, the terms “upstream” (or “forward”) and “downstream” (or“aft”) refer to the relative direction with respect to fluid flow in afluid pathway. For example, “upstream” refers to the direction fromwhich the fluid flows, and “downstream” refers to the direction to whichthe fluid flows. The term “radially” refers to the relative directionthat is substantially perpendicular to an axial centerline of aparticular component, the term “axially” refers to the relativedirection that is substantially parallel and/or coaxially aligned to anaxial centerline of a particular component and the term“circumferentially” refers to the relative direction that extends aroundthe axial centerline of a particular component. Terms of approximation,such as “generally,” “substantially,” “approximately,” or “about”include values within ten percent greater or less than the stated value.When used in the context of an angle or direction, such terms includewithin ten degrees greater or less than the stated angle or direction.For example, “generally vertical” includes directions within ten degreesof vertical in any direction, e.g., clockwise or counter-clockwise.

The terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting. As used herein, thesingular forms “a,” “an,” and “the” are intended to include the pluralforms as well, unless the context clearly indicates otherwise. It willbe further understood that the terms “comprises” and/or “comprising,”when used in this specification, specify the presence of statedfeatures, integers, steps, operations, elements, and/or components, butdo not preclude the presence or addition of one or more other features,integers, steps, operations, elements, components, and/or groupsthereof.

Referring now to the drawings, FIG. 1 illustrates a schematic diagram ofone embodiment of a turbomachine, which in the illustrated embodiment isa gas turbine 10. Although an industrial or land-based gas turbine isshown and described herein, the present disclosure is not limited to aland based and/or industrial gas turbine unless otherwise specified inthe claims. For example, the invention as described herein may be usedin any type of turbomachine including but not limited to a steamturbine, an aircraft gas turbine, or a marine gas turbine.

As shown, the gas turbine 10 generally includes an inlet section 12, acompressor 14 disposed downstream of the inlet section 12, a combustionsection 16 disposed downstream of the compressor 14, a turbine 18disposed downstream of the combustion section 16, and an exhaust section20 disposed downstream of the turbine 18. Additionally, the gas turbine10 may include one or more shafts 22 that couple the compressor 14 tothe turbine 18.

During operation, air 24 flows through the inlet section 12 and into thecompressor 14 where the air 24 is progressively compressed, thusproviding compressed air 26 to the combustion section 16. At least aportion of the compressed air 26 is mixed with a fuel 28 within thecombustion section 16 and burned to produce combustion gases 30. Thecombustion gases 30 flow from the combustion section 16 into the turbine18, wherein energy (kinetic and/or thermal) is transferred from thecombustion gases 30 to rotor blades (not shown), thus causing shaft 22to rotate. The mechanical rotational energy may then be used for variouspurposes, such as to power the compressor 14 and/or to generateelectricity. The combustion gases 30 exiting the turbine 18 may then beexhausted from the gas turbine 10 via the exhaust section 20.

FIG. 2 provides an upstream view of the combustion section 16, accordingto various embodiments of the present disclosure. As shown in FIG. 2,the combustion section 16 may be at least partially surrounded by anouter or compressor discharge casing 32. The compressor discharge casing32 may at least partially define a high pressure plenum 34 that at leastpartially surrounds various components of the combustor 16. The highpressure plenum 34 may be in fluid communication with the compressor 14(FIG. 1) so as to receive the compressed air 26 therefrom. In variousembodiments, as shown in FIG. 2, the combustion section 16 includes asegmented annular combustion system 36 that includes a number ofintegrated combustor nozzles 100 arranged circumferentially around anaxial centerline 38 of the gas turbine 10, which may be coincident withthe gas turbine shaft 22.

FIG. 3 provides a perspective view of an integrated combustor nozzle100, as viewed from a first side. Similarly, FIG. 4 provides aperspective view of an integrated combustor nozzle 100, as viewed from asecond side, in accordance with embodiments of the present disclosure.As shown collectively in FIGS. 2, 3 and 4, the segmented annularcombustion system 36 includes a plurality of integrated combustornozzles 100. As described further herein, each combustor nozzle 100includes a first side wall 116 and a second side wall 118. In particularembodiments, the first side wall is a pressure side wall, while thesecond side wall is a suction side wall, based on the integration of theside walls with corresponding pressure and suction sides of a downstreamturbine nozzle 120. It should be understood that any references madeherein to pressure side walls and suction side walls are representativeof particular embodiments, such references being made to facilitatediscussion, and that such references are not intended to limit the scopeof any embodiment, unless specific context dictates otherwise.

As shown collectively in FIGS. 3 and 4, each circumferentially adjacentpair of combustor nozzles 100 defines a respective primary combustionzone 102 and a respective secondary combustion zone 104 therebetween,thereby forming an annular array of primary combustion zones 102 andsecondary combustion zones 104. The primary combustion zones 102 and thesecondary combustion zones 104 are circumferentially separated, orfluidly isolated, from adjacent primary combustion zones 102 andsecondary combustion zones 104, respectively, by the combustion liners110.

As shown collectively in FIGS. 3 and 4, each combustor nozzle 100includes an inner liner segment 106, an outer liner segment 108, and ahollow or semi-hollow combustion liner 110 that extends between theinner liner segment 106 and the outer liner segment 108. It iscontemplated that more than one (e.g., 2, 3, 4, or more) combustionliners 110 may be positioned between the inner liner segment 106 and theouter liner segment 108, thereby reducing the number of joints betweenadjacent liner segments that require sealing. For ease of discussionherein, reference will be made to integrated combustor nozzles 100having a single combustion liner 110 between respective inner and outerliner segments 106, 108, although a 2:1 ratio of liner segments tocombustion liners is not required. As shown in FIGS. 3 and 4, eachcombustion liner 110 includes forward or upstream end portion 112, anaft or downstream end portion 114, a first side wall 116, which is apressure side wall in the particular example embodiment illustrated inFIG. 3 and a second side wall 118, which is a suction side wall in theparticular example embodiment illustrated in FIG. 4.

The segmented annular combustion system 36 further includes a fuelinjection module 117. In the illustrated example embodiment, the fuelinjection module 117 includes a plurality of fuel nozzles. The fuelinjection module 117 is configured for installation in the forward endportion 112 of a respective combustion liner 110. For purposes ofillustration herein, the fuel injection module 117 including theplurality of fuel nozzles may be referred to as a “bundled tube fuelnozzle.” However, the fuel injection module 117 may include or compriseany type of fuel nozzle or burner (such as a swirling fuel nozzle orswozzle), and the claims should be not limited to a bundled tube fuelnozzle unless specifically recited as such.

Each fuel injection module 117 may extend at least partiallycircumferentially between two circumferentially adjacent combustionliners 110 and/or at least partially radially between a respective innerliner segment 106 and outer liner segment 108 of the respectivecombustor nozzle 100. During axially staged fuel injection operation,the fuel injection module 117 provides a stream of premixed fuel and air(that is, a first combustible mixture) to the respective primarycombustion zone 102.

In at least one embodiment, as shown in FIGS. 3 and 4, the downstreamend portion 114 of one or more of the combustion liners 110 transitionsinto a generally airfoil-shaped turbine nozzle 120, which directs andaccelerates the flow of combustion products toward the turbine blades.Thus, the downstream end portion 114 of each combustion liner 110 may beconsidered an airfoil without a leading edge. When the integratedcombustor nozzles 100 are mounted within the combustion section 16, theturbine nozzle 120 may be positioned immediately upstream from a stageof turbine rotor blades of the turbine 18.

As used herein, the term “integrated combustor nozzle” refers to aseamless structure that includes the combustion liner 110, the turbinenozzle 120 downstream of the combustion liner, the inner liner segment106 extending from the forward end 112 of the combustion liner 110 tothe aft end 114 (embodied by the turbine nozzle 120), and the outerliner segment 108 extending from the forward end 112 of the combustionliner 110 to the aft end 114 (embodied by the turbine nozzle 120). In atleast one embodiment, the turbine nozzle 120 of the integrated combustornozzle 100 functions as a first-stage turbine nozzle and is positionedupstream from a first stage of turbine rotor blades.

As described above, one or more of the integrated combustor nozzles 100is formed as an integral, or unitary, structure or body that includesthe inner liner segment 106, the outer liner segment 108, the combustionliner 110, and the turbine nozzle 120. The integrated combustor nozzle100 may be made as an integrated or seamless component, via casting,additive manufacturing (such as 3D printing), or other manufacturingtechniques. By forming the combustor nozzle 100 as a unitary orintegrated component, the need for seals between the various features ofthe combustor nozzle 100 may be reduced or eliminated, part count andcosts may be reduced, and assembly steps may be simplified oreliminated. In other embodiments, the combustor nozzle 100 may befabricated, such as by welding, or may be formed from differentmanufacturing techniques, where components made with one technique arejoined to components made by the same or another technique.

In particular embodiments, at least a portion or all of each integratedcombustor nozzle 100 may be formed from a ceramic matrix composite (CMC)or other composite material. In other embodiments, a portion or all ofeach integrated combustor nozzle 100 and, more specifically, the turbinenozzle 120 or its trailing edge, may be made from a material that ishighly resistant to oxidation (e.g., coated with a thermal barriercoating) or may be coated with a material that is highly resistant tooxidation.

In another embodiment (not shown), at least one of the combustion liners110 may taper to a trailing edge that is aligned with a longitudinal(axial) axis of the combustion liner 110. That is, the combustion liner110 may not be integrated with a turbine nozzle 120. In theseembodiments, it may be desirable to have an uneven count of combustionliners 110 and turbine nozzles 120. The tapered combustion liners 110(i.e., those without integrated turbine nozzles 120) may be used in analternating or some other pattern with combustion liners 110 havingintegrated turbine nozzles 120 (i.e., integrated combustor nozzles 100).

At least one of the combustion liners 110 may include at least onecross-fire tube 122 that extends through respective openings in thepressure side wall 116 and the suction side wall 118 of the respectivecombustion liner 110. The cross-fire tube 122 permits cross-fire andignition of circumferentially adjacent primary combustion zones 102between circumferentially adjacent integrated combustor nozzles 100.

In many embodiments, as shown in FIG. 3, each combustion liner 110 mayinclude a plurality of radially spaced pressure side injection outlets164 defined along the pressure side wall 116, through which the pressureside fuel injectors 160 may extend (FIG. 6). As shown in FIG. 4, eachcombustion liner 110 may include a plurality of radially spaced suctionside injection outlets 165 defined along the suction side wall 118,through which the suction side fuel injectors 161 may extend (FIG. 6).Each respective primary combustion zone 102 is defined upstream from thecorresponding pressure side injection outlets 164 and/or suction sideinjection outlets 165 of a pair of circumferentially adjacent integratedcombustor nozzles 100. Each secondary combustion zone 104 is defineddownstream from the corresponding pressure side injection outlets 164and/or suction side injection outlets 165 of the pair ofcircumferentially adjacent integrated combustor nozzles 100. Althoughthe plurality of pressure side injection outlets 164 are shown in FIG. 2as residing in a common radial or injection plane with respect to anaxial centerline of the integrated combustor nozzle 100 or at a commonaxial distance from the downstream end portion 114 of the fuel injectionpanel 110, in particular embodiments, one or more of the pressure sideinjection outlets 164 may be staggered axially with respect to radiallyadjacent pressure side injection outlets 164, thereby off-setting theaxial distances of the pressure side injection outlets 164 to thedownstream end portion 114 for particular pressure side injectionoutlets 164. Similarly, although FIG. 4 illustrates the plurality ofsuction side injection outlets 165 in a common radial or injection planeor at a common axial distance from the downstream end portion 114 of thefuel injection panel 110, in particular embodiments, one or more of thesuction side injection outlets 165 may be staggered axially with respectto radially adjacent suction side injection outlets 165, therebyoff-setting the axial distances of the pressure side injection outlets165 to the downstream end portion 114 for particular suction sideinjection outlets 165.

During operation of the segmented annular combustion system 36, it maybe necessary to cool one or more of the pressure side walls 116, thesuction side walls 118, the turbine nozzle 120, the inner liner segments106, and/or the outer liner segments 108 of each integrated combustornozzle 100 in order to enhance mechanical performance of each integratedcombustor nozzle 100 and of the segmented annular combustion system 36overall. In order to accommodate cooling requirements, each integratedcombustor nozzle 100 may include various air passages or cavities, andthe various air passages or cavities may be in fluid communication withthe high pressure plenum 34 formed within the compressor dischargecasing 32 and/or with the premix air plenum 144 defined within eachcombustion liner 110.

FIG. 5 illustrates a perspective view of an integrated combustor nozzle100, which is shown having various cooling components exploded away, inaccordance with embodiments of the present disclosure. In variousembodiments, as shown, an interior portion of each combustion liner 110may be defined between the pressure side wall 116 and the suction sidewall 118 and may be partitioned into various air passages or cavities124, 126 by one or more ribs 128, 129. In particular embodiments, theair cavities 124, 126 may receive air from the compressor dischargecasing 32 or other cooling source. The ribs or partitions 128, 129 mayextend within the interior portion of the combustion liner 110 to atleast partially form or separate the plurality of air cavities 124, 126.In particular embodiments, some or all of the ribs 128, 129 may providestructural support to the pressure side wall 116 and/or the suction sidewall 118 of the combustion liner 110.

In particular embodiments, as shown in FIG. 5, each integrated combustornozzle 100 may include one or more outer impingement panels 130 thatextends along an exterior surface 131 of the outer liner segment 108.The outer impingement panels 130 may have a shape corresponding to theshape, or a portion of the shape, of the outer liner segment 108. Inmany embodiments, the outer impingement panel 130 may define a pluralityof impingement holes 139 defined at various locations along the outerimpingement panel 130 (FIG. 7). In many embodiments, as shown best inFIGS. 3 and 4, the outer impingement panels 130 may be disposed bothsides of the cavities 124, 126, in order to provide impingement coolingto the entire outer liner segment 108.

Similarly, each integrated combustor nozzle 100 may include an innerimpingement panel 134 that extends along an exterior surface 135 of theinner liner segment 106. The inner impingement panel 134 may have ashape corresponding to the shape, or a portion of the shape, of theinner liner segment 106. In many embodiments, as shown best in FIGS. 3and 4, the inner impingement panel 134 may be disposed on both sides ofthe cavities 124, 126, in order to provide impingement cooling to theentire inner liner segment 106.

As shown in FIG. 5, one or more of the integrated combustor nozzles 100may further include cooling inserts 400 that are positioned proximatethe forward end 112 of the combustion liner 110 and an impingementcooling apparatus 300 that is positioned proximate the aft end 114 ofthe combustion liner 110. As shown and described in detail below, thecooling inserts may be positioned within the cavity 124, such that thecooling inserts 400 are housed within the interior of the combustionliner 110 to provide cooling thereto. Similarly, the impingement coolingapparatus 300 may be housed within the cavity 126, such that theimpingement cooling apparatus 300 is housed within the interior of thecombustion liner 110 to provide cooling thereto. As described in moredetail below, both the cooling inserts 400 and the impingement coolingapparatus 300 may be formed as a substantially hollow (or semi-hollow)structure, with an opening at one or both ends, in a shape complementaryto the air cavity 126. During operation, air from the compressordischarge casing 32 may flow through one or both of the cooling inserts400 and/or the impingement cooling apparatus 300, where the air may flowthrough impingement holes as discrete jets, which impinge on interiorsurfaces of the combustion liner 110 thereby allowing heat to transferconvectively from the interior surfaces of the combustion liner 110 tothe cooling air. As discussed in detail below, after impinging on theinterior surfaces of the combustion liner 110, a portion of the airpassed through the cooling insets 400 and/or the impingement coolingapparatus 300 may be flowed through the combustion liner 110 towards thefuel injectors where the air may be mixed with fuel and used forcombustion in the secondary combustion zone 104. In this way, the airthat is used for cooling the combustion liner 110 is also used toproduce work in the turbine section 18, thereby increasing the overallefficiency of the gas turbine 10.

In many embodiments, as shown, two cooling inserts 400 may be installedwithin the air cavity 124, such as a first cooling insert 400 installedthrough the inner liner segment 106 and a second cooling insert 400installed through the outer liner segment 108. Such an assembly may beuseful when the integrated combustor nozzle 100 includes a cross-firetube 122 that prevents insertion of a single impingement air insert 400through the radial dimension of the cavity 124. Alternately, two or moreimpingement air inserts 400 may be positioned sequentially in the axialdirection A (the axial direction A is indicated, e.g., in FIG. 6) withina given cavity, e.g., on either side of the cross-fire tube 122.

FIG. 6 illustrates a cross-sectional schematic view of an integratedcombustor nozzle 100, in accordance with embodiments of the presentdisclosure. As shown in FIG. 6, the integrated combustor nozzle 100 mayfurther include a pressure side fuel injector 160. In many embodiments,the integrated combustor nozzle 100 may include a plurality of pressureside fuel injectors 160 spaced apart from one another along the radialdirection R. For example, each of the pressure side fuel injectors 160may extend from an inlet 162 positioned within the combustion liner 110proximate the suction side wall 118 to the pressure side injectionoutlet 164. Similarly, in many embodiments, the integrated combustornozzle 100 may include a plurality of suction side fuel injectors 161spaced apart from one another along the radial direction R. For example,each of the suction side fuel injectors 161 may extend from an inlet 166positioned within the combustion liner 110 proximate the pressure sidewall 116 to the suction side injection outlet 165. The fuel injectors160, 161 may provide a secondary mixture of fuel and air to thesecondary combustion zone 104 downstream from the primary combustionzone 102, in order to increase the temperature of the combustion gasesbefore they enter the turbine section 18 and are used to produce work.

In various embodiments, as shown in FIG. 6, the fuel injectors 160, 161may be positioned axially between the cooling insert(s) 400 and theimpingement cooling apparatus 300. In particular embodiments, thepressure side fuel injector 160 may be positioned axially between theimpingement cooling apparatus 300 and the suction side fuel injector161. Likewise, the suction side fuel injector 161 may be positionedaxially between the cooling insert(s) 400 and the pressure side fuelinjector 160.

In particular embodiments, the integrated combustor nozzle 100 mayinclude a frame 168 and ribs 128, 129. The frame 168 may extend aroundand support the fuel injectors 160, 161. Further, the frame 168 may atleast partially define a path for air to travel before entering the fuelinjectors 160, 161. Each of the ribs 128, 129 may extend between thepressure side wall 116 and the suction side wall 118. As shown in FIG.6, the ribs 128, 129 may include one or more openings definedtherethrough in order to provide for fluid communication between thefuel injectors 160, 161 and the cooling insert 400 or the impingementcooling apparatus 300.

As shown, the various arrows illustrate the flow path of air within thecombustion liner 110. For example, the integrated combustor nozzle 100may further include pre-impingement air 152 and post-impingement air orspent cooling air 154. As shown in FIG. 6, the pre-impingement air 152may exit the cooling insert 400 via a first plurality of impingementapertures 404 (FIG. 24) and a second plurality of impingement apertures405 (FIG. 25) defined on each of the walls 402, 403, respectively.Similarly, pre-impingement air 152 may exit the impingement coolingapparatus 300 via a plurality of impingement apertures 304 defined oneach of the impingement members 302 (FIG. 17). The impingement apertures304, 404, 405 may be sized and oriented to direct the pre-impingementair 152 in discrete jets to impinge upon the interior surface 156 of thepressure side wall 116 or the interior surface 158 of the suction sidewall 118. The discrete jets of air impinge (or strike) the interiorsurface 156,158 and create a thin boundary layer of air over theinterior surface 156, 158, which allows for optimal heat transferbetween the walls 116, 118 and the air. For example, the impingementapertures 304, 404, 405 may orient pre-impingement air such that it isperpendicular to the surface upon which it strikes, e.g. the interiorsurface 156, 158 of the walls 116, 118. Once the air has impinged uponthe interior surface 156, 158, it may be referred to as“post-impingement air” and/or “spent cooling air” because the air hasundergone an energy transfer and therefore has differentcharacteristics. For example, the spent cooling air 154 may have ahigher temperature and lower pressure than the pre-impingement air 152because the spent cooling air 154 has removed heat from the combustionliner 110 during the impingement process.

Referring to the flow path of air exiting the impingement coolingapparatus 300, as shown in FIG. 6, pre-impingement air 152 exits each ofthe impingement members 302 via the plurality of impingement apertures304 and impinges upon the interior surfaces 156, 158 of the side walls116, 118. At which point, the air undergoes an energy transfer byremoving heat from the side walls 116, 118 and thus becomingpost-impingement air 154. The post-impingement air 154 then reversesdirections and flows through gaps 172 (FIG. 18) defined between theimpingement members 302. As shown in FIG. 6, the impingement coolingapparatus 300 may further define a collection passageway 174 thatreceives post-impingement air 154 from the gaps 172 defined between theimpingement members 302. Both the gaps 172 and the collection passageway174 favorably provide a path for the post-impingement air 154 to travelaway from the pre-impingement air 152. This is advantageous because itprevents the post-impingement air 154 from impeding, i.e. flowing acrossand disrupting, the flow of pre-impingement air 152, which allows thepre-impingement air 152 to maintain its high velocity and cool the walls116, 118 effectively. Once the post-impingement air 154 is within thecollection passageway 174, it may flow in a direction generally oppositeto the axial direction A, i.e. opposite the direction of combustiongases. As shown in FIG. 6, the post-impingement air 154 may flow fromthe collection passageway 174, through the one or more holes defined inthe rib 129, around the pressure side fuel injector 160, and into theinlet 166 of the suction side fuel injector 161. In this way, all of theair that flows through impingement cooling apparatus 300 is utilized forboth impingement cooling and combustion gas generation, which minimizesthe amount of wasted air from the compressor section 14 and thereforeincreases the overall performance of the gas turbine 10.

Referring now to the flow path of air exiting the cooling insert 400, asshown in FIG. 6, pre-impingement air 152 may exit the walls 402, 403 viathe plurality of impingement apertures 404, 405 and impinge upon theinterior surfaces 156, 158 of the side walls 116, 118. At which point,the air undergoes an energy transfer by removing heat from the sidewalls 116, 118 and thus becoming post-impingement air 154. Then aportion post-impingement air 154 then changes directions and flows in adirection opposite to the axial direction A, i.e., opposite thedirection of combustion gases. As shown in FIG. 6, the post-impingementair 154 may then reverse directions and travel through a collectionpassageway 406, that is defined between the walls 402, 403. Thecollection passageway 406 may direct the post impingement air 154towards the pressure side fuel injector 160. In this way, the collectionpassageway 406 favorably provides a path for the post-impingement air154 to travel that is away from the pre-impingement air 152. This isadvantageous because it prevents the post-impingement air 154 fromimpeding, i.e., flowing across and disrupting, the flow ofpre-impingement air 152, which allows the pre-impingement air 152 tomaintain its high velocity and cool the walls 116, 118 effectively. Oncethe post-impingement air 154 is within the collection passageway 406, itmay be guided towards the inlet 162 of the pressure side fuel injector160. For example, the post-impingement air 154 may flow from thecollection passageway 406, through the one or more openings defined inthe rib 128, around the suction side fuel injector 161, and into theinlet 162 of the pressure side fuel injector 160. In this way, all ofthe air that flows through the cooling insert 400 is utilized for bothimpingement cooling and combustion gas generation, which minimizes theamount of wasted air from the compressor section 14 and thereforeincreases the overall performance of the gas turbine 10.

FIG. 7 illustrates an enlarged cross-sectional view of a portion of theouter liner segment 108, and FIG. 8 illustrates an enlargedcross-sectional view of a portion of the inner liner segment 106, inaccordance with exemplary embodiments of the integrated combustor nozzle100. In many embodiments, the integrated combustion nozzle 100 mayinclude an outer impingement panel 130 and an inner impingement panel134 on either side of the combustion liner 110, in order to provideimpingement cooling to the entire outer liner segment 108 and innerliner segment 106.

As shown in FIGS. 7 and 8, both the outer impingement panel 130 and theinner impingement panel 134 may include an impingement plate 136 that isdisposed along the exterior surfaces 131, 135 of the outer liner segment108 and the inner liner segment 106, respectively. For example, theimpingement plate 136 of the outer impingement panel 130 may be disposedalong the exterior surface 131, i.e. radially outer surface, of theouter liner segment 108. Similarly, the impingement plate 136 of theinner impingement panel 134 may be disposed along the exterior surface135, i.e. radially inner surface, of the inner liner segment 106. Inexemplary embodiments, as shown, each impingement plate 136 may bespaced from the respective exterior surfaces 131, 135 along the radialdirection R to form a cooling flow gap 138 therebetween. For example,with respect to the outer impingement panels 130, the impingement plates136 may be spaced outwardly from the exterior surface 131 of the outerliner segment along the radial direction R, thereby forming the coolingflow gap 138 therebetween. Similarly, the impingement plates 136 of theinner impingement panels 134 may be spaced inward from the exteriorsurface 135 of the inner liner segment 106 along the radial direction R,thereby forming the cooling flow gap 138 therebetween.

As shown in FIGS. 7 and 8, the various arrows may represent the flowpath of air within the impingement panels 130, 134. In exemplaryembodiments, the high pressure plenum 34 may be in fluid communicationwith the cooling flow gap 138 via a plurality of impingement holes 139that are defined through the impingement plates 136 along the radialdirection R. Specifically, the impingement holes 139 may be sized andoriented to direct pre-impingement air 152 from the high pressure plenum34 in discrete jets to impinge upon the exterior surface 131, 135 of theouter liner segment 108 and the inner liner segment 106. The discretejets of pre-impingement air 152 may then impinge (or strike) theexterior surface 131, 135 and create a thin boundary layer of air overthe exterior surface 131, 135, which allows for optimal heat transferbetween the liner segments 106, 108 and the air. Once the air hasimpinged upon the exterior surface 131, 135, it may be referred to as“post-impingement air” and/or “spent cooling air” because the air hasundergone an energy transfer and therefore has differentcharacteristics. For example, the spent cooling air 154 may have ahigher temperature and lower pressure than the pre-impingement air 152because it has removed heat from the combustion liner segments 106, 108during the impingement process.

In exemplary embodiments, an inlet portion 140 extends from theimpingement plate 136 to a collection duct 142. As shown in FIG. 7, thecollection duct 142 may define a collection passage 144 that receivespost impingement air 154 from the cooling flow gap 138 via the inletportion 140 and guides the post impingement air 154 towards the lowpressure inlet 408 of the cooling insert 400 to be utilized within thefuel injectors 160, 161 (FIG. 6). In many embodiments, as shown in FIG.7, the inlet portion 140 may provide a passageway between the coolingflow gap 138 and the collection passage 144. For example, the inletportion 140 may extend directly from the impingement plate 136 to thecollection duct 142, such that the inlet portion 140 directly fluidlycouples the cooling flow gap 138 to the collection passage 144. Invarious embodiments, as shown in FIG. 10, the inlet portion 140 mayinclude side walls 150 spaced apart from one another. The side walls 150may extend axially along the impingement plate 130, parallel to oneanother, such that they define an elongated slot shaped opening 188(FIG. 11) through the impingement plate 136 for the passage ofpost-impingement air 154.

In particular embodiments, as shown in FIG. 10, each collection duct 142may have a cross-sectional shape that defines a rectangular area. Forexample, each collection duct 142 may include a radially inward wall146, a radially outward wall 148, and side walls 141 that extend betweenthe radially inward wall 146 and the radially outward wall 148. Inparticular embodiments, the side walls 141 of the collection duct 142may be parallel to one another and longer than the radiallyinward/outward walls 146, 148, which advantageously allows thecollection duct 142 to have a large collection area without overlappingthe impingement holes 139 and causing an impediment to the airflowbetween the high pressure plenum 34 and the cooling flow gap 138. Inother embodiments (not shown), the collection duct may have any suitablecross sectional shape, such as a circle, oval, diamond, square, or othersuitable polygonal shape, and should therefore not be limited to anyparticular cross sectional shape unless specifically recited in theclaims.

As shown in FIG. 10, the inlet portion 140 may define a first width 176and the collection duct 142 may define a second width 178. Morespecifically, the first width 176 may be defined between the side walls150 of the inlet portion 140. Similarly, the second width 178 of thecollection duct 142 may be defined between the side walls 141 of thecollection duct 142. It may be advantageous to have the first width 176be as small as possible relative to the second width 178 of thecollection duct 142, in order to maximize the amount of area that can beimpingement cooled by the impingement plate 136. For example, inexemplary embodiments, the second width 178 of the collection duct 142may be larger than the first width 176 of the inlet portion 140.

In many embodiments, as shown in FIG. 9, the collection duct 142 may bea first collection duct 142′, and the impingement panel 130 may furtherinclude a second collection duct 142″ that extends from the impingementpanel 130. As shown, the first collection duct 142′ and the secondcollection duct 142″ may be spaced apart from one another and may extendgenerally parallel to one another in the axial direction A. In suchembodiments, each collection duct 142′, 142″ may be coupled to theimpingement plate 136 via respective inlet portions 140, which providesa passageways between the cooling flow gap 138 and the collectionpassages 144. For example, the respective inlet portions 140 may eachextend directly from the impingement plate 136 to the collection duct142, such that they directly fluidly couple the cooling flow gap 138 tothe respective collection passages 144.

FIG. 9 illustrates a plan view along the radial direction R of twoimpingement panels 131 and a cooling insert 400 isolated from the othercomponents of the integrated combustor nozzle. As shown in FIG. 9, theimpingement panels 131 may be representative of either or both of theouter impingement panel 130 and/or the inner impingement panel 134. Inmany embodiments, each of the impingement panels 130 may couple to thelow pressure inlet 408 of the cooling insert 400. In particularembodiments, each of the collection ducts 142 may couple to the lowpressure inlet 408 via a connection duct 180. In some embodiments (notshown), the collection ducts 142 may couple directly to the respectivelow pressure inlets 408 of the cooling insert 400. As discussed below indetail, the low pressure inlets 408 of the cooling insert 400 may be indirect fluid communication with the collection passageway 406, andtherefore in fluid communication with the suction side fuel injector161. In this way, the collection ducts 142 advantageously provide apassageway for post-impingement air 154 to travel to a fuel injectorwhere they may be used to produce combustion gases within the secondarycombustion zone 104.

In many embodiments the impingent panels 130 may be a singular body thatextends continuously from a forward end to an aft end. However, inexemplary embodiments, as shown in FIG. 9 the impingement panels 130 mayinclude a plurality of panel segments 182 coupled to one another. Forexample, in many embodiments, the impingement panel 130 may include twopanel segments 182, such as a forward segment 184 and an aft segment 186coupled together. In other embodiments, the impingement panel mayinclude three or more segments, such as a forward segment 184, a middlesegment 185, and an aft segment 186. In such embodiments, the forwardsegment 184 and the aft segment 186 may each independently couple to themiddle segment 185, as shown. Dividing the impingement panels 130 intopanel segments 182 may advantageously allow for an increased number ofimpingement panels 130 to be manufactured, such as through additivemanufacturing, at one time, which can result in production cost savings.

As illustrated by the hidden lines in FIG. 11, the inlet portion 140 ofeach of the panel sections 182 may further define an elongated slotopening 188 through the respective impingement plates 136 that allowspost impingement air 154 to flow from the cooling gap into thecollection duct 142. In some embodiments (not shown), the elongated slotopening 188 may be continuous between the panel segments 182.

In various embodiments, as shown in FIG. 9, each of the collection ducts142 may converge in cross sectional from a forward end 190 to an aft end192, i.e., in the axial direction A. More specifically, the side walls141 of the collection duct 142 may converge towards one another from theforward end 190 to the aft end of the impingement panel 130, therebygradually reducing the second width 178 and the cross-sectional area ofthe collection duct 142 as it extends in the axial direction A.Gradually reducing the cross-sectional area of the collection duct 142from a forward end 190 to an aft end 192 of the impingement panel 130may favorably influence the post impingement air 154 to flow towards thecooling insert 400, i.e., in a direction opposite the axial direction.

In operation, the collection duct 142 may receive spent cooling air fromthe cooling flow gap 138. As used herein, the terms “post-impingementair” and/or “spent cooling air” refer to air that has already impingedupon a surface and therefore undergone an energy transfer. For example,the spent cooling air may have a higher temperature and lower pressurethan prior to having impinged upon the exterior surface 131, 135, whichmakes the spent cooling air nonideal for further cooling within theintegrated combustion nozzle. However, the collection duct 142advantageously collects the spent cooling air and directs it towards oneor more fuel injectors, e.g., the fuel injection module 117 and/or oneor both fuel injectors 160 and 161, for use in either the primarycombustion zone 102 or the secondary combustion zone 104. In this way,the impingement panel 130 efficiently utilizes air from the highpressure plenum 34 by first utilizing the air to cool the liner segments106, 108 and then using the air to produce combustion gases that powerthe turbine section 18.

In many embodiments, each of the panel segments 182 may be integrallyformed as a single component. That is, each of the subcomponents, e.g.,the impingement plate 136, the inlet portion 140, the collection duct142, and any other subcomponent of the panel segments 182, may bemanufactured together as a single body. In exemplary embodiments, thismay be done by utilizing the additive manufacturing system 1000described herein. However, in other embodiments, other manufacturingtechniques, such as casting or other suitable techniques, may be used.In this regard, utilizing additive manufacturing methods, each panelsegment 182 of the impingement panel 130 may be integrally formed as asingle piece of continuous metal, and may thus include fewersub-components and/or joints compared to prior designs. The integralformation of each panel segment 182 through additive manufacturing mayadvantageously improve the overall assembly process. For example, theintegral formation reduces the number of separate parts that must beassembled, thus reducing associated time and overall assembly costs.Additionally, existing issues with, for example, leakage, joint qualitybetween separate parts, and overall performance may advantageously bereduced. In some embodiments, the entire impingement panel 130 may beintegrally formed as a single component.

FIG. 10 illustrates a cross sectional view of a panel segment 182 of theimpingement panel 130 from along the axial direction A, and FIG. 11illustrates plan view of a panel segment 182 from along the radialdirection R, in accordance with embodiments of the present disclosure.It will be appreciated that the features of the panel segment 182 shownin FIGS. 10 and 11 can be incorporated into any of the panel segmentsdescribed herein, such as forward segment 184, middle segment 185,and/or the aft segment 186.

As shown in FIGS. 10 and 11, the panel segment 182 may further includeone or more supports 194 that extend between, and are integrally formedwith, the inlet portion 140, the collection duct 142, and theimpingement plate 136, in order to provide structural support thereto.In various embodiments, each support 194 may be shaped substantially asa flat plate that extends between the impingement plate 136 and thecollection duct 142. In particular embodiments, each support 194 mayextend from a first end 196 integrally formed with to the impingementplate 136 to a second end 198 integrally formed with the collection duct142. In exemplary embodiments, the support 194 may be fixedly coupled tothe panel segment 182, e.g., the support 194 may be a separate componentthat is welded and/or brazed on to the panel segment 182. Utilizing thesupports 194 in this way provides additional structural integrity to thecollection duct 142, which may advantageously prevent damage to theimpingement panel 130 caused from vibrational forces of the gas turbine10 during operation.

In particular embodiments, each of the supports 194 includes a firstside 197 and a second side 199 that extend between the first end 196 andthe second end 198 of each of the supports 194, i.e., between theimpingement plate 136 and the collection duct 142. As shown in FIG. 10,the first end 196, second end 198, first side 197, and second side 199may collectively define the perimeter of the support 194. In manyembodiments, the first side 197 of the support 194 extends along and isintegrally formed with one of the side walls 150 of the inlet portion140. In exemplary embodiments, the second side 199 of the support 194may be a generally straight line that extends from the impingement plate136 at an angle 200.

For example, in many embodiments, the second side 199 of each support194 may form an angle 200 of between about 10° and about 75° with theimpingement plate 136. In other embodiments, the second side 199 of eachsupport 194 may form an angle 200 of between about 20° and about 65°with the impingement plate 136. In various embodiments, the second side199 of each support 194 may form an angle 200 of between about 30° andabout 55° with the impingement plate 136. In particular embodiments, thesecond side 199 of each support 194 may form an angle 200 of betweenabout 40° and about 50° with the impingement plate 136.

In exemplary embodiments, the angle 200 of the second side 199 mayadvantageously provide additional structural support to the impingementpanel 130, thereby preventing vibrational damage to the impingementpanel 130 during operation of the gas turbine 10. In addition, the angle200 of the second side 199, may provide additional structural support tothe collection duct 142 during the additive manufacturing process of theimpingement panel 130, which advantageously reduces the likelihood ofdistortion and/or defects in the impingement panel 130. For example, theangle 200 of the second side 199 relative to the impingement plate 136discussed herein may prevent the support 194 from overhanging, i.e.having excessive thick-to-thin variation, while being fabricated usingthe additive manufacturing system 1000 (FIG. 15). As a result, theimpingement panel 130, which would otherwise be difficult to manufacturevia traditional means due to its complex geometry, may be fabricatedusing an additive manufacturing system 1000 without causing defects ordeformations in the part.

As shown in FIG. 11, the each of the supports 194 may form an angle 202with the inlet portion 140 (shown as dashed lines in FIG. 11). Morespecifically, each of the supports 194 may form the angle 202 with theside wall 150 of the inlet portion 140. In many embodiments, the angle202 may be oblique, which favorably allows the support 194 to extendfurther along the impingement plate 136. However, in other embodiments(not shown), the one or more of the supports 194 may be perpendicular tothe inlet portion 140.

In various embodiments, the angle 202 between the side wall 150 of theinlet portion 140 and the support 194 may be between about 10° and about90°. In other embodiments, the angle 202 between the side wall 150 ofthe inlet portion 140 and the support 194 may be between about 20° andabout 70°. In particular embodiments, the angle 202 between the sidewall 150 of the inlet portion 140 and the support 194 may be betweenabout 30° and about 60°. In many embodiments, the angle 202 between theside wall 150 of the inlet portion 140 and the support 194 may bebetween about 40° and about 50°.

As shown in FIG. 11, the panel segment 182 may further include centeraxis 206, which may be generally parallel to the side walls 150 of theinlet portion 140. In many embodiments, when the panel segment 182 isinstalled in an integrated combustor 100, the center axis 206 may extendcoaxially with the axial direction A the gas turbine 10. In otherembodiments, the center axis 206 may extend generally parallel to theaxial direction A, when the panel segment is installed in an integratedcombustor nozzle 100.

FIG. 12 illustrates a cross-sectional perspective view of a panelsegment 182, in accordance with embodiments of the present disclosure.The panel segment 182 may extend from a first end 208, along the centeraxis 206 (FIG. 11), to a second end 210. FIG. 13 illustrates a plan viewof an exemplary embodiment of the first end 208 of the panel segment 182from along the center axis 206, and FIG. 14 illustrates the second end210 of the panel segment 182 from along the center axis 206.

As shown in FIG. 13, the first end 208 of the panel segment 182 includesa flange 212 that extends from the impingement panel. In variousembodiments, the flange 212 may be a generally flat plate that extendsfrom first end 208 of the panel segment 182. More specifically, theflange 212 may be perpendicular to, and extend away from, theimpingement plate 136, the inlet portion 140, and the collection duct142 at the first end 208 of the panel segment 182, in order to define aconnection surface 213 (FIG. 13). The connection surface 213advantageously allows multiple panel segments 182 to be fixedly coupledtogether, by a means such as welding, brazing, or other suitablemethods. In many embodiments, the flange 212 may also increase theoverall rigidity and structural integrity of the panel segment 182,thereby preventing vibrational damage that could be caused to thecomponent during operation of the gas turbine 10.

In many embodiments, the flange 212 may be integrally formed with thepanel segment 182, such that the collection plate 136, the inlet portion140, the collection duct 142, and the flange 212 may be a single pieceof continuous metal. In such embodiments, the flange 212 may alsoprovide manufacturing advantages. For example, the flange 212 generallysurrounds the features of the panel segment 182 and provides additionalstructural support for the collection duct 142 during the additivemanufacturing process.

As shown in FIG. 14, in some embodiments, the second end 210 of theimpingement panel 182 may not include the flange 212 that is integrallyformed therewith, as is the case with the first end 208. As indicated bythe dashed line in FIG. 14, an end plate 211 may be attached to thesecond end 210 and fixedly coupled thereto. For example, the end plate211 may be an entirely separate component from the impingement panelsegment 182. In many embodiments, the end plate 211 may be welded orbrazed to the second end 210 after the manufacturing of the impingementpanel segment 182 is complete. The end plate 211, which is fixedlycoupled to the second end 210, may have a substantially similar geometryas the flange 212, but is a separate component rather than beingintegrally formed. The end plate 211 may function to couple the secondend 210 of the impingement panel segment 182 to the first end 208 of aneighboring impingement panel segment (as shown in FIG. 9). In exemplaryembodiments, the end plate 211 of an impingent panel segment 182 may befixedly coupled to the flange 212 of a neighboring impingement panelsegment 182. Coupling the impingement panel segments 182 in this way maybe advantageous because the end plate 211 and the flange 212 arerelatively flat and smooth surfaces that provide for an easy and errorfree weld therebetween. In other embodiments, both the first end 208 andthe second end 210 may include a flange 212, in which the flange 212 ofthe first end 208 of a panel segment 182 may fixedly couple to theflange 212 of the second end 210 of a neighboring panel segment 182.

To illustrate an example of an additive manufacturing system andprocess, FIG. 15 shows a schematic/block view of an additivemanufacturing system 1000 for generating an object 1220, such as thepanel segments 182, the cooling insert 400, and/or the impingementcooling apparatus 300 described herein. FIG. 15 may represent anadditive manufacturing system configured for direct metal lasersintering (DMLS) or direct metal laser melting (DMLM). The additivemanufacturing system 1000 fabricates objects, such as the object 1220(which may be representative of the panel segments 182, the coolinginsert 400, and/or the impingement cooling apparatus 300 describedherein). For example, the object 1220 may be fabricated in alayer-by-layer manner by sintering or melting a powder material (notshown) using an energy beam 1360 generated by a source such as a laser1200. The powder to be melted by the energy beam is supplied byreservoir 1260 and spread evenly over a build plate 1002 using arecoater arm 1160 to maintain the powder at a level 1180 and removeexcess powder material extending above the powder level 1180 to wastecontainer 1280. The energy beam 1360 sinters or melts a cross sectionallayer of the object being built under control of the galvo scanner 1320.The build plate 1002 is lowered and another layer of powder is spreadover the build plate and the object being built, followed by successivemelting/sintering of the powder by the laser 1200. The process isrepeated until the object 1220 is completely built up from themelted/sintered powder material. The laser 1200 may be controlled by acomputer system including a processor and a memory. The computer systemmay determine a scan pattern for each layer and control laser 1200 toirradiate the powder material according to the scan pattern. Afterfabrication of the object 1220 is complete, various post-processingprocedures may be applied to the object 1220. Post processing proceduresinclude removal of excess powder by, for example, blowing or vacuuming.Other post processing procedures include a stress release process.Additionally, thermal and chemical post processing procedures can beused to finish the object 1220.

FIG. 16 is a flow chart of a sequential set of steps 1602 through 1606,which define a method 1600 of fabricating an impingement panel (such asone of the impingement panels 130, 131, 134 described herein), inaccordance with embodiments of the present disclosure. The method 1600may be performed using an additive manufacturing system, such as theadditive manufacturing system 1000 described herein or another suitablesystem. As shown in FIG. 16, the method 1600 includes a step 1602 ofirradiating a layer of powder in a powder bed 1120 to form a fusedregion. In many embodiments, as shown in FIG. 15, the powder bed 1120may be disposed on the build plate 1002, such that the fused region isfixedly attached to the build plate 1002. The method 1600 may include astep 1604 of providing a subsequent layer of powder over the powder bed1120 from a first side of the powder bed 1120. The method 1600 furtherincludes a step 1606 of repeating steps 1602 and 1604 until theimpingement panel is formed in the powder bed 1120.

FIG. 17 illustrates a perspective view of the impingement coolingapparatus 300, which is isolated from the integrated combustor nozzleand positioned on a build plate 1002, and in which one of theimpingement members in a row has been cut away. As discussed below, theimpingement cooling apparatus 300 may be additively manufactured on abuild plate 1002, e.g., by the additive manufacturing system 1000. FIG.17 depicts the impingement cooling apparatus 300 prior to removal fromthe build plate 1002 and installation into the integrated combustornozzle 100, in accordance with embodiments of the present disclosure.

As shown in FIG. 17, the impingement cooling apparatus 300 may extend inthe radial direction R, which may coincide with the build direction,from a first end 306 to a second end 308. In many embodiments, theimpingement cooling apparatus 300 includes a plurality of impingementmembers 302, which are arranged in a first row 320 of impingementmembers 302 and a second row 322 of impingement members 302. Eachimpingement member 302 in the first row 320 of impingement members 302may extend from a first flange 310 at the first end 306 to a respectiveclosed end 312 at the second end 308 of the impingement coolingapparatus 300. Similarly, each impingement member 302 in the second row322 of impingement members 302 may extend from a second flange 311 atthe first end 306 to a respective closed end 312 at the second end 308of the impingement cooling apparatus 300. In this way, the first row 320and the second row 322 of impingement members 302 may each be singularcomponents capable of movement relative to one another duringinstallation into the cavity 126, which advantageously allows thedistance between the rows 320, 322 of impingement members 302 and thewalls 116, 118 to be independently set from one another.

In other embodiments, each impingement member 302 may be its ownentirely separate component, which is capable of movement relative tothe other impingement members 302 in the impingement cooling apparatus300. In such embodiments, each impingement member 302 may extend from arespective flange. In embodiments where each impingement member 302 is aseparate component, the impingement members may be installedindividually within the integrated combustor nozzle (i.e. one at atime), and each standoff 356, 358 may serve to ensure that a properlysized gap is disposed between each impingement member 302 during boththe installation of the impingement members 302 and the operationthereof.

In exemplary embodiments, each of the impingement members 302 may besubstantially hollow bodies that extend from a respective opening 313defined in the flanges 310, 311 to a respective closed end 312 (FIG.19). Although the embodiment in FIG. 17 shows an impingement coolingapparatus 300 having eleven impingement cooling members 302, theimpingement cooling apparatus 302 may have any number of impingementmembers 302, e.g., 4, 6, 8, 12, 14, or more. In various embodiments, asshown in FIG. 17, each impingement member 302 in the plurality ofimpingement members 302 may be spaced apart from directly neighboringimpingement members 302, in order to define the gap 172 forpost-impingement air 154 to flow between impingement members 302 andinto the collection passageway 174 (FIG. 6). In many embodiments, aplurality of impingement apertures 304 may be defined on eachimpingement member 302 of the plurality of impingement members 302

FIG. 18 depicts an enlarged cross-sectional view of the integratedcombustor nozzle 100 from along the radial direction R, in which theimpingement cooling apparatus 300 is positioned within the cavity 126.As shown in FIG. 18, the integrated combustor nozzle 100 may furtherinclude a camber axis 318, which may be defined halfway between thepressure side wall 116 and the suction side wall 118. For example, thecamber axis 318 may be curved and/or contoured to correspond with thecurve of the pressure side wall 116 and the suction side wall 118. Atransverse direction T may be defined orthogonally with respect to thecamber axis 138. More specifically, the transverse direction T mayextend outward from, and perpendicular to, a line that is tangent to thecamber axis 318 at each location along the camber axis 318.

In particular embodiments, each impingement member 302 of the pluralityof impingement members 302 includes an impingement wall 314 spaced apartfrom a solid wall 316. In exemplary embodiments, the plurality ofimpingement apertures may be defined on the impingement wall 314, inorder to direct pre-impingement air 152 towards the interior surface156, 158 of the walls 116, 118 (FIG. 6). The solid wall 316 may beoppositely disposed from the impingement wall 314. In many embodiments,the solid wall 314 of each respective impingement member 302 may bedirectly outward of the camber axis 318 along the transverse directionT, such that solid walls 316 of the impingement member 302 collectivelydefine the boundary of the collection passageway 174. As used herein,the term “solid” may refer to a wall or walls that are impermeable, suchthat they do not allow air or other fluids to pass therethrough. Forexample, the each of the solid walls 316 may not have any impingementapertures, holes, or voids that would allow for pre-impingement air 152to escape, in order to ensure all of the air gets directed towards theinterior surface 156, 158 of the walls 116, 118 for cooling.

In particular embodiments, as shown in FIG. 18, the plurality ofimpingement members 302 may include a first row 320 of impingementmembers 302 disposed proximate the pressure side wall 116 and a secondrow 322 of impingement members 320 disposed proximate the suction sidewall 118. For example, the first row 320 and the second row 322 ofimpingement members may be disposed on opposite sides of the camber axis318, such that they are spaced apart in the transverse direction T. Asshown in FIG. 18, the collection passageway 174 may be defined betweenthe first row 320 and the second row 322 of impingement members 302.More specifically, the collection passageway 174 may be definedcollectively between the solid walls 316 of the first row 320 ofimpingement members 302 and the solid walls 316 of the second row 322 ofimpingement members 302. As shown in FIG. 6 and discussed above, thecollection passageway 174 may function to receive post impingement air154 and direct it towards a fuel injector, such as the suction side fuelinjector 161 (FIG. 6).

In particular embodiments, the first row 320 of impingement members 302and the second row 322 of impingement members diverge away from eachother from an aft end 324 to a forward end 326 of impingement coolingapparatus 300, i.e., opposite the direction of combustion gases withinthe combustion zones 102, 104. For example, the first row 320 ofimpingement members 302 and the second row 322 of impingement membersdiverge away from each other in the transverse direction from an aft end324 to a forward end 326 of impingement cooling apparatus 300. In thisway, the transverse distance between impingement members 302 of thefirst row 320 and impingement members 302 of the second row 322 maygradually increase from the aft end 324 to the forward end 326, therebyinfluencing post-impingement air 154 to travel towards the suction sidefuel injector 161.

As shown in FIG. 18, the impingement wall 314 of each respectiveimpingement member 302 on the first row 320 may be contoured tocorrespond with a portion of pressure side wall 116, such that theimpingement walls 314 of the first row 320 collectively correspond tothe contour of the pressure side wall 116. Similarly, the impingementwall 314 of each respective impingement member 302 on the second row 322may be contoured to correspond with a portion of the suction side wall118, such that the impingement walls 314 of the second row 322collectively correspond to the contour of the suction side wall 118.Matching the contour of the walls 116, 118 advantageously maintains adesired transverse distance from the respective walls 116, 118. In manyembodiments, the transverse distance between the impingement walls 314and the respective walls 116, 118 may be generally constant.

In particular embodiments, each impingement member 302 of the pluralityof impingement members 302 may include a first solid side wall 328 and asecond solid side wall 330 that each extend between the impingement wall314 and the solid wall 316. As shown in FIG. 18, the first solid sidewall 328 and the second solid side wall 330 of each impingement member302 may be spaced apart and oppositely disposed from one another. Invarious embodiments, the first solid wall 328 and second side wall 330of each impingement member 302 may be generally parallel to one anotherin the transverse direction T. As shown in FIG. 18, the first solid sidewall 328, the second solid wall 330, the impingement wall 314, and thesolid wall 316 of each impingement member of the plurality ofimpingement members collectively defines an internal volume 332 that isin fluid communication with the high pressure plenum 34. In exemplaryembodiments, each of the impingement members 302 may define a generallyrectangular cross-sectional area. However, in other embodiments (notshown), the each of the impingement members 302 may define a crosssectional area having a circular shape, a diamond shape, a triangularshape, or other suitable cross-sectional shapes.

In particular embodiments, as shown in FIGS. 6, 18 and 20, a gap 172 maybe defined between directly neighboring impingement members 302, whichadvantageously provides a path for post impingement air 154 to travelinto the collection passageway 174. In various embodiments, each of thegaps 172 may be defined directly between the first side wall 328 of animpingement member and the second side wall 330 of a directlyneighboring impingement member 302. In this way, each impingement member302 of the plurality of impingement members 302 partially defines atleast one gap 172. As shown in FIG. 18, each of the gaps 172 may bedefined between the first side wall 328 of an impingement member 302 andthe second side wall 330 of a neighboring impingement member 302 in adirection generally parallel to the camber axis 318 at their respectivelocations. In other embodiments (not shown), each impingement member 302may define a diamond shaped cross-sectional area. In such embodiments,the first side wall 328 and the second side wall 330 may be angledrelative to the camber axis, which may advantageously reduce thepressure drop of the impingement air.

FIG. 19 depicts a cross-sectional view of a single impingement member302 from along the camber axis 318. FIG. 20 illustrates an enlargedcross-sectional view of an impingement member 302 and a portion of twoneighboring impingement members 302 from along the radial direction R,in accordance with embodiments of the present disclosure. It should beappreciated that the features of impingement member 302 shown in FIGS.19 and 20 may be incorporated into any of the impingement members 302 inthe plurality of impingement members 302 described herein. In exemplaryembodiments, as shown in FIGS. 19 and 20, the impingement member 302 mayfurther include a first protrusion 334, a second protrusion 335, and aplurality of cross-supports 346 extending therebetween. In manyembodiments, the first protrusion may 334 be disposed on the impingementwall 314, the second protrusion 335 may be disposed on the solid wall316, and the plurality of cross-supports 346 may each extend from thefirst protrusion 334, through the internal volume 332, to the secondprotrusion 335. Each of the protrusions 334, 335 may extend from therespective walls 314, 316 towards an axial centerline 336 (FIG. 19) ofthe impingement member 302. More specifically, the first protrusion 334may extend directly from an interior surface 338 of the impingement wall314 towards the axial centerline 336. Likewise, the second protrusion335 may extend directly from an interior surface 340 of the solid wall316 towards the axial centerline 336. In various embodiments, the firstprotrusion 334 may extend radially along the entire length of theimpingement wall 314, e.g., between the open end 313 and the closed end312 of the impingement member 302.

In particular embodiments, as shown in FIG. 20, each protrusion 334, 335may include first portion 342 that extends generally perpendicularlybetween the respective walls 314, 316 and a second portion 344. Thesecond portion 344 of each protrusion 334, 335 may extend generallyperpendicularly to the respective first portions 342, such that theprotrusions 334, 335 each define a T-shaped cross section. Theprotrusions 334, 335 advantageously improve the rigidity of each of theimpingement members 302, and therefore they improve the rigidity of theoverall impingement cooling apparatus 300. Increased rigidity of theimpingement cooling apparatus 300 may prevent damage caused byvibrational forces of the gas turbine 10 during operation. For example,the protrusions 334, 335 may give the impingement cooling apparatus 300a more desirable natural frequency, in order to prevent failures of theimpingement cooling apparatus 300 caused by minute oscillations of theintegrated combustion nozzle 100.

As shown in FIGS. 19 and 20, each of the cross-supports 346 may includea first support 348 bar and a second support bar 350, which intersectwith one another at an intersection point 352 (FIG. 19) disposed withinthe internal volume 332 of the impingement member 302. In particularembodiments, the first support bar 348 and the second support bar 350 ofeach of the cross-supports 346 may extend between the first protrusion334 and the second protrusion 335. More specifically, the first supportbar 348 and the second support bar 350 of each of the cross-supports 346may extend directly between the second portions 344 of the firstprotrusion 334 and the second portion 344 of the second protrusion 335.In other embodiments (not shown), the first support bar 348 and thesecond support bar 350 of each of the cross-supports may extend directlybetween the interior of the impingement wall and the interior of thesolid wall, such that there are no protrusions present.

In many embodiments, as shown in FIG. 19, the first support bar 348 andthe second support bar may each form an angle 354 with the flange 310that is oblique, i.e., not parallel or perpendicular. For example, insome embodiments, the first support bar 348 and the second support bar350 may each form an angle 354 with the flange 310 that is between about15° and about 75°. In other embodiments, the first support bar 348 andthe second support bar 350 may each form an angle 354 with the flange310 that is between about 25° and about 65°. In various embodiments, thefirst support bar 348 and the second support bar 350 may each form anangle 354 with the flange 310 that is between about 35° and about 55°.In particular embodiments, the first support bar 348 and the secondsupport bar 350 may each form an angle 354 with the flange 310 that isbetween about 40° and about 50°. The angle 354 advantageously provideadditional structural integrity and internal bracing to each of theimpingement members 302, which prevents damage due to the vibrationalforces of the gas turbine 10. Additionally, as discussed below, theangle 354 of the support bars 348, 350 allows the impingement members302 to be additively manufactured without defects or deformation. Forexample, when being additively manufactured layer by layer, such as withthe additive manufacturing system 1000 described herein, the angle ofthe support bars 348, 350 advantageously prevents the cross-supports 346from otherwise detrimental overhang, which could cause deformationand/or a total collapse of the component. For example, a support barextending perpendicularly across the impingement member 302 may bedifficult and/or impossible to manufacture using an additivemanufacturing system. Thus, the angle 354 between the support bars 348,350 and the flange 310 is favorable.

In many embodiments, as shown in FIGS. 17-20 collectively, theimpingement cooling apparatus 300 may further include stand-offs 356,358 that extend from each of the impingement members 302. The stand-offs356, 358 may be shaped as substantially flat plates that extendoutwardly from the impingement members 302. In many embodiments, thestand-offs may space apart each impingement member 302 from surroundingsurfaces, such as neighboring impingement members 302 and/or the walls116, 118 of the combustion liner 110. The stand-offs 356, 358 may beconfigured to keep the impingement members 302 at the desired distancefrom the surrounding surfaces, in order to optimize the impingementcooling of the combustion liner 310 and the recirculation of the postimpingement air 154 into the collection passageway 174.

In particular embodiments, the stand-offs may include side wallstand-offs 356 and impingement wall stand-offs 358. As shown in FIG. 17,in many embodiments, at least one side wall stand-off 356 and at leastone impingement wall stand-off 358 may be disposed proximate the flange310, 311 on each impingement member 302. in various embodiments, atleast one side wall stand-off 356 and at least one impingement wallstand-off 358 may disposed proximate the closed end 312 of eachimpingement member 302 of the plurality of impingement members 302.Arranging the stand-offs 356, 358 proximate the first end 306 and secondend 308 of the impingement cooling apparatus 300 may advantageouslyprovide more uniform support and spacing between neighboring impingementmembers 302 and between impingement members 302 and the walls 116, 118of the combustion liner 110.

In particular embodiments, as shown in FIG. 20, the side wall stand-offs356 may each extend from and couple the first solid side wall 328 of animpingement member 302 to the second solid side wall 330 of aneighboring impingement member 302. In exemplary embodiments, the lengthof the side wall stand-offs 356 may set the distance of the gap 172 andmay couple adjacent impingement members 302 together. For example, theimpingement members 302 in a row, e.g. the first row 320 and/or secondrow 322, may be linked to the neighboring impingement members 302 withinthat row via one or more of the side wall stand-offs 356. In this way,the side wall stand-offs 356 function to maintain adequate space betweenthe impingement members 302. In addition, the side wall stand-offs 356advantageously prevent deformation of the relatively slender impingementmembers 302 during the additive manufacturing process by providingadditional structural support to the impingement cooling apparatus 300.

In various embodiments, as shown in FIGS. 18, The impingement wallstand-offs 358 may function to maintain adequate space between theimpingement members 302 and one of the walls 116, 118 of the combustionliner 110. For example, in exemplary embodiments, the impingement wallstand-offs 358 may extend from the impingement wall 314 and contact oneof the walls 116, 118 of the combustion liner 310, which may be one ofthe first side wall 116 or the second side wall 118 of the combustionliner 310. For example, unlike the side wall stand-offs 356, theimpingement wall stand-offs 358 are not coupled on both ends, but theyare integrally formed with the impingement wall 314 on one end and incontact with the interior surface of either the pressure side wall 116or the suction side wall 118 once the impingement cooling apparatus 300is installed into the combustion liner 110. In this way, the impingementwall stand-offs 358 may be removably coupled to the combustion liner110. In exemplary embodiments, the length of the side wall stand-offs358 may set the distance of the gap disposed between the impingementwall 314 and the wall 116 or 118 of the combustion liner 310.

FIGS. 21 and 22 illustrate an enlarged view of an impingement wallstand-off 358 extending from an impingement wall 314 of an impingementmember 302 to one of the walls 116, 118 of the combustion liner 310(shown as a dashed line), in accordance with embodiments of the presentdisclosure. More specifically, FIG. 20 illustrates an impingement wallstand-off 358 immediately after being manufactured, e.g., by theadditive manufacturing system 1000, but prior to any post machining. Inmany embodiments, each of the impingement wall stand-offs may bemanufactured having excess material or length 360, as illustrated by thelength 360 of the stand-off 358 that extends beyond the wall 116 or 118.As shown in FIG. 21, the excess material or length 360 of the stand-off358 may be removed, in order to maintain the desired tolerance betweenthe impingement wall 314 and the wall 116, 118 for optimal coolingperformance.

Although FIG. 22 illustrates an exemplary embodiment of an impingementwall stand-off 358 of the impingement cooling apparatus 300, FIG. 21 maybe representative of the various other stand-offs disclosed herein (suchas the stand-offs disposed on the impingement panel 130 and/or thestand-offs disposed on the cooling insert 400).

In particular embodiments, each row of impingement members 320, 322 inthe impingement cooling apparatus 300 may be integrally formed as asingle component. That is, each of the subcomponents, e.g., one of theflanges 310, 311, the impingement members 302, the first protrusion 334,the second protrusion 335, the plurality of cross supports346, thestand-offs 356, 358, and any other subcomponent of each row 320, 322 ofimpingement members 302, may be manufactured together as a single body.In exemplary embodiments, this may be done by utilizing the additivemanufacturing system 1000 described herein. However, in otherembodiments, other manufacturing techniques, such as casting or othersuitable techniques, may be used. In this regard, utilizing additivemanufacturing methods, each row 320, 322 of impingement members 302 maybe integrally formed as a single piece of continuous metal, and may thusinclude fewer sub-components and/or joints compared to prior designs.The integral formation of each row 320, 322 of impingement members 302through additive manufacturing may advantageously improve the overallassembly process. For example, the integral formation reduces the numberof separate parts that must be assembled, thus reducing associated timeand overall assembly costs. Additionally, existing issues with, forexample, leakage, joint quality between separate parts, and overallperformance may advantageously be reduced. In some embodiments (notshown), the entire impingement cooling apparatus 300 may be integrallyformed as a single component. In such embodiments, the impingementcooling apparatus may have a single flange, rather than a first flange310 and a second flange 311, from which all of the impingement members302 extend.

FIG. 23 is a flow chart of a sequential set of steps 2302 through 2306,which define a method 2300 of fabricating an impingement coolingapparatus 300, in accordance with embodiments of the present disclosure.The method 2300 may be performed using an additive manufacturing system,such as the additive manufacturing system 1000 described herein oranother suitable system. As shown in FIG. 23, the method 2300 includes astep 2302 of irradiating a layer of powder in a powder bed 1120 to forma fused region. In many embodiments, as shown in FIG. 15, the powder bedmay be disposed the build plate 1002, such that the fused region isfixedly attached to the build plate 1002. The method 2300 may include astep 2304 of providing a subsequent layer of powder over the powder bed1120 from a first side of the powder bed 1120. The method 2300 furtherincludes a step 2306 of repeating steps 2302 and 2304 until theimpingement cooling apparatus 300 is formed in the powder bed 1120.

FIG. 24 illustrates a perspective view of a cooling insert 400, which isisolated from the other components of the integrated combustor nozzle100, in accordance with embodiments of the present disclosure. As shownin FIG. 24, the cooling insert 400 may extend between a first end 410and a second end 412. In many embodiments, the cooling insert 400includes a flange 414 that extends between and generally surrounds thewalls 402, 403 at the first end 410 of the cooling insert 400. In manyembodiments, the flange 414 may define one or more openings that providefluid communication between cooling insert 400, the high pressure plenum34, and/or one or more of the impingement panels 130 described herein.In various embodiments, the flange 414 may couple the cooling insert 400to one of the inner liner segment 106 or the outer liner segment 108. Asdiscussed below in more detail, the flange 414 may define both the firstopen end 418 and the second open end 428, in order to provide fluidcommunication between the high pressure plenum 34 and the first wall andsecond wall of the cooling insert 400. In this way, the first open end418 and the second open 428 end defined within the flange 414 may serveas a high pressure air inlet. In many embodiments, the cooling insert400 may further include a low pressure inlet 408 defined within theflange 414. As shown best in FIGS. 6 and 9, the low pressure inlet 408may provide for fluid communication between the collection ducts 142 ofthe impingement panels 130 and the collection passageway 406 of thecooling insert 400 (FIG. 9).

FIG. 25 illustrates a cross-sectional view of a cooling insert 400 fromalong the axial direction A, FIG. 26 illustrates a cross-sectional viewfrom along the radial direction R, and FIG. 27 illustrates across-sectional of a cooling insert 400 from along the circumferentialdirection C, in accordance with embodiments of the present disclosure.As shown in FIG. 25, the cooling insert 400 may include an axialcenterline 401 that extends between the walls 402, 403 of the coolinginsert. In exemplary embodiments, when the cooling insert 400 isinstalled into an integrated combustor nozzle 100, the axial centerline401 may coincide with the radial direction R of the gas turbine 10.

As shown in FIG. 25, the cooling insert 400 may include a first wall 402that defines a first passage 416 therein. As shown, the first wall 402may extend generally radially from a first open end 418 defined withinthe flange 414 to a first closed end 420. In this way, the first wall402 may be a substantially hollow body that receives air from the highpressure plenum 34 via the first open end 418 defined in the flange 414.In particular embodiments, the first wall 410 includes a firstimpingement side 422 spaced apart from a first solid side 424. As shown,the first passage 416 may be defined directly between the firstimpingement side 422 and the first solid side 424. In variousembodiments, the first impingement side 422 may define a first pluralityof impingement apertures 404, which may be configured to direct air fromthe first passage 416 towards the first side wall (e.g. the pressureside wall 116) of the combustion liner 110 (FIG. 5). In manyembodiments, the first plurality of impingement apertures 404 may besized and oriented to direct the pre-impingement air 152 in discretejets to impinge upon the interior surface 156 of the pressure side wall116. The discrete jets of air impinge (or strike) the interior surface156 and create a thin boundary layer of air over the interior surface156 which allows for optimal heat transfer between the pressure sidewall 116 and the air.

Similarly, the cooling insert 400 may further include a second wall 403spaced apart from the first wall 402. In many embodiments, the secondwall 403 may define a second passage 426 therein. As shown, the firstwall 402 may extend generally radially from a second open end 428defined within the flange 414 to a second closed end 430. In this way,the second wall 403 may be a substantially hollow body that receives airfrom the high pressure plenum 34 via the second open end 428 defined inthe flange 414. In particular embodiments, the second wall 403 includesa second impingement side 432 spaced apart from a second solid side 434.As shown, the second passage 426 may be defined directly between thesecond impingement side 432 and the second solid side 434. In variousembodiments, the second impingement side 432 may define a secondplurality of impingement apertures 405, which may be configured todirect air from the second passage 426 towards the second side wall(e.g. the suction side wall 118) of the combustion liner 110 (FIG. 5).In many embodiments, the second plurality of impingement apertures 405may be sized and oriented to direct the pre-impingement air 152 indiscrete jets to impinge upon the interior surface 158 of the suctionside wall 118. The discrete jets of air impinge (or strike) the interiorsurface 158 (FIG. 6) and create a thin boundary layer of air over theinterior surface 158 which allows for optimal heat transfer between thesuction side wall 118 and the air.

As used herein, the term “solid” may refer to a wall or walls that areimpermeable, such that they do not allow air or other fluids to passtherethrough. For example, the first solid side 424 and the second solidside 434 may not have any impingement apertures, holes, or voids thatwould allow for pre-impingement air 152 to escape, in order to ensureall of the air gets directed towards the interior surface 156, 158 ofthe walls 116, 118 for cooling.

As shown in FIG. 25, the first wall 402 may include a first row 436 ofsupports 438 that extend between first impingement side 422 and thefirst solid side 424. For example, in some embodiments each support 438may extend directly between the first impingement side 422 and the firstsolid side 424, such that they advantageously provide additionalstructural integrity to the first wall 402. As shown in FIG. 25, eachsupport 438 in the first row 436 of supports 438 may form an obliqueangle 440 with the first solid side 424, which allows the supports 438to be manufactured with the first wall 402 via an additive manufacturingsystem (such as the additive manufacturing system 1000 describedherein). For example, in many embodiments, each support 438 in the firstrow 436 of supports 438 may form an oblique angle 440 with the firstsolid side wall 424 that is between about 10° and about 80°. In otherembodiments, each support 438 in the first row 436 of supports 438 mayform an oblique angle 440 with the first solid side wall 424 that isbetween about 20° and about 70°. In particular embodiments, each support438 in the first row 436 of supports 438 may form an oblique angle 440with the first solid side wall 424 that is between about 30° and about60°. In many embodiments, each support 438 in the first row 436 ofsupports 438 may form an oblique angle 440 with the first solid sidewall 424 that is between about 40° and about 50°.

Likewise, the second wall 403 may include a second row 442 of supports444 that extend between second impingement side 432 and the second solidside 434. For example, in some embodiments each support 444 in thesecond row 442 of supports 444 may extend directly between the secondimpingement side 432 and the second solid side 434, such that theyadvantageously provide additional structural integrity to the secondwall 403. As shown in FIG. 25, each support 444 in the second row 442 ofsupports 444 may form an oblique angle 446 with the second solid side434, which allows the supports 444 to be manufactured with the secondwall 403 via an additive manufacturing system (such as the additivemanufacturing system 1000 described herein). For example, the in manyembodiments, each support 444 in the second row 442 of supports 444 mayform an oblique angle 446 with the second solid side wall 434 that isbetween about 10° and about 80°. In other embodiments, each support 444in the second row 442 of supports 444 may form an oblique angle 446 withthe second solid side wall 434 that is between about 20° and about 70°.In particular embodiments, each support 444 in the second row 442 ofsupports 444 may form an oblique angle 446 with the second solid sidewall 434 that is between about 30° and about 60°. In many embodiments,each support 444 in the second row 442 of supports 444 may form anoblique angle 446 with the second solid side wall 434 that is betweenabout 40° and about 50°.

The oblique angle 440, 446 of the supports 438, 444 allows the walls402, 403 to be additively manufactured with minimal or no defects ordeformation. For example, when being additively manufactured layer bylayer, such as with the additive manufacturing system 1000 describedherein, the oblique angle 440, 446 of the supports 438, 444advantageously prevents the supports 438, 444 from otherwise detrimentaloverhang, which could cause deformation and/or a total collapse of thecomponent. For example, a support extending perpendicularly across theimpingement may be difficult and/or impossible to manufacture using anadditive manufacturing system. Thus, the oblique angle 440, 446 betweenthe supports 438, 444 and solid wall 424, 434 is favorable.

As shown in FIG. 26, the first impingement side 422 may include a firstcontour that corresponds with the first wall, e.g., the pressure sidewall 116. Similarly, in many embodiments, the second impingement sidemay include a second contour that corresponds with the second wall,e.g., the suction side wall 116. In this way, the impingement sides 422,432 may each maintain a constant spacing from the respective side walls116, 118 in the axial direction A, which optimizes impingement coolingthereto. As used herein, a contours that “correspond” with one anothermay mean two or more walls or surfaces that each have matching orgenerally identical curvatures in one or more directions.

In many embodiments, as shown in FIG. 26, the first impingement side 422may diverge away from the first solid wall 424 as they extend in theaxial direction A. Similarly, the second impingement side 432 maydiverge away from the second solid wall 434 as they extend in the axialdirection A. More specifically, the first wall 402 may include a firstparallel portion 448 and a first diverging portion 450. The firstparallel portion 448 of the first wall 402 may be disposed proximate theforward end of the cooling insert 400. As shown in FIG. 26, in the firstparallel portion 448, the first impingement side 422 may be generallyparallel to the first solid side 424. The first diverging portion 450 ofthe first wall 402 may extend continuously from the first parallelportion 448. In the first diverging portion 450, the first impingementside 422 may gradually diverge away from the first solid wall 424 asthey extend in the axial direction A, such that the gap between thewalls gradually increases in the axial direction A. Likewise, the secondwall 403 may include a second parallel portion 452 and a seconddiverging portion 454. The second parallel portion 452 of the secondwall 403 may be disposed proximate the forward end of the cooling insert400. As shown in FIG. 26, in the second parallel portion 452, the secondimpingement side 432 may be generally parallel to the second solid side434. The second diverging portion 454 of the second wall 403 may extendcontinuously from the second parallel portion 452. In many embodiments,in the second diverging portion 452, the second impingement side 432 maygradually diverge away from the second solid wall 434 as they extend inthe axial direction A, such that the gap between the walls graduallyincreases in the axial direction A.

In particular embodiments, a collection passageway 406 may be definedbetween the first solid side 424 and the second solid side 434. Forexample, in many embodiments, the first solid side 424 and the secondsolid side 434 may be spaced apart from one another, such that thecollection passageway 406 is defined therebetween. In many embodiments,the first solid side 424 and the second solid side 434 may each besubstantially flat plates that extend parallel to one another in boththe axial direction A and the radial direction R. The collectionpassageway 406 may receive low pressure air (relative to the highpressure pre-impingement air) from one or more sources and guide saidlow pressure air to a fuel injector 160, 161 for usage in the secondarycombustion zone 104. For example, the collection passageway 406 mayreceive a first source of low pressure air from one or more of theimpingement panel 130 collection ducts 142, which is coupled to thecooling insert 400 via the low pressure inlet 408 defined within theflange 414. Another source of low pressure air for the collectionpassageway 406, as shown in FIG. 6, may be post-impingement air 154,which has exited the impingement sides and impinged upon the walls 116,118.

As shown in FIGS. 24-27 collectively, at one or more guide vanes 456 mayextend between the first solid side 424 and the second solid side 434,in order to guide low pressure air towards the fuel injectors 160, 161.In various embodiments, each guide vane 456 may extend directly betweenthe first solid side 424 and the second solid side 434, thereby couplingthe first wall 402 of the cooling insert 400 to the second wall 403 ofthe cooling insert 400. In particular embodiments, the guide vane 456may be disposed within the collection passageway 406 such that lowpressure air may travel along the guide vane 456 towards the fuelinjectors 160, 161. In many embodiments, each of the guide vanes 456 mayinclude an arcuate portion 458 and a straight portion 460 that extendcontinuously with one another. The arcuate portion 458 may be disposedproximate the forward end of the cooling insert 400. The straightportion 460 of the guide vane 456 may extend from the arcuate portion458 towards the aft end of the cooling insert 400. In many embodiments,the straight portion 460 of the guide vane may be generally parallel tothe axial direction A when the cooling insert is installed in anintegrated combustor nozzle 100.

As shown in FIGS. 24-26 collectively, the first impingement side mayinclude a first set of stand-offs 462 that, when the cooling insert 400is installed within an integrated combustor nozzle 100, extend from thefirst impingement side 422 to the first side wall (e.g. the pressureside wall 116). Similarly, in many embodiments, the second impingementside includes a second set of stand-offs 464 that extend from the secondimpingement side 432 to the second side wall (e.g. the suction side wall118). Each set of stand-offs 462, 464 may function to maintain adequatespace between the impingement sides 422, 432 and one of the walls 116,118 of the combustion liner 110. For example, in exemplary embodiments,the stand-offs may extend from each respective impingement side andcontact a wall 116, 118 of the combustion liner 110. For example,stand-offs are not coupled on both ends, but they are integrally formedwith the impingement side 422, 432 on one end and in contact with theinterior surface of either the pressure side wall 116 or the suctionside wall 118 once the cooling insert 400 is installed into thecombustion liner 110. In this way, the stand-offs 462, 464 may beremovably coupled to the combustion liner 110. In exemplary embodiments,the length of the stand-offs 462, 464 may set the distance of the gapdisposed between the impingement side and the wall 116, 118 of thecombustion liner 110.

FIG. 28 illustrates an enlarged view of two oppositely disposed coolinginserts 400, in accordance with embodiments of the present disclosure.More specifically, FIG. 25 illustrates the closed end 420 of twooppositely disposed cooling inserts 400. In particular embodiments, eachclosed end 420 may include an arcuate portion 466 that curves around thecross fire tube 122. In other embodiments (not shown), in which thecross fire tube is not preset, the closed ends may extend straightacross (e.g. in the axial direction A).

In many embodiments, each of the cooling inserts 400 may be integrallyformed as a single component. That is, each of the subcomponents, e.g.,the first wall 402, the second wall 403, the flange 414, the guidevane456, the standoffs 462, 464, and any other subcomponent of thecooling insert 400, may be manufactured together as a single body. Inexemplary embodiments, this may be done by utilizing the additivemanufacturing system 1000 described herein. However, in otherembodiments, other manufacturing techniques, such as casting or othersuitable techniques, may be used. In this regard, utilizing additivemanufacturing methods, the cooling insert 400 may be integrally formedas a single piece of continuous metal, and may thus include fewersub-components and/or joints compared to prior designs. The integralformation of the cooling insert 400 through additive manufacturing mayadvantageously improve the overall assembly process. For example, theintegral formation reduces the number of separate parts that must beassembled, thus reducing associated time and overall assembly costs.Additionally, existing issues with, for example, leakage, joint qualitybetween separate parts, and overall performance may advantageously bereduced.

This written description uses examples to disclose the invention,including the best mode, and also to enable any person skilled in theart to practice the invention, including making and using any devices orsystems and performing any incorporated methods. The patentable scope ofthe invention is defined by the claims, and may include other examplesthat occur to those skilled in the art. Such other examples are intendedto be within the scope of the claims if they include structural elementsthat do not differ from the literal language of the claims, or if theyinclude equivalent structural elements with insubstantial differencesfrom the literal language of the claims.

What is claimed is:
 1. An impingement panel configured to provideimpingement cooling to an exterior surface, the impingement panelcomprising: an impingement plate disposed along the exterior surface,wherein the impingement plate defines a plurality of impingementapertures that direct coolant in discrete jets towards the exteriorsurface; a collection duct spaced apart from the impingement plate anddefining a collection passage; an inlet portion extending from theimpingement plate to the collection duct; and at least one supportcoupled to the impingement plate and at least one of the inlet portionand the collection duct.
 2. The impingement panel as in claim 1, whereinthe at least one support extends between and is coupled to the inletportion, the collection duct, and the impingement plate.
 3. Theimpingement panel as in claim 1, wherein the at least one supportextends from a first end fixedly coupled to the impingement plate to asecond end fixedly coupled to the collection duct.
 4. The impingementpanel as in claim 3, wherein the at least one support includes a firstside and a second side that extend between the first end and the secondend, and wherein the first side is fixedly coupled to the inlet portion.5. The impingement panel as in claim 4, wherein the second side of theat least one support forms an angle with the impingement plate that isbetween about 10° and about 75°.
 6. The impingement panel as in claim 1,wherein the at least one support forms an angle with the inlet portionthat is between about 10° and about 90°.
 7. The impingement panel as inclaim 1, wherein the impingement panel comprises a plurality ofimpingement panel segments coupled together.
 8. The impingement panel asin claim 7, wherein each impingement panel segment of the plurality ofimpingement panel segments extends between a first end of theimpingement panel segment and a second end of the impingement panelsegment, and wherein the first end includes a flange that extends fromthe impingement plate of the impingement panel segment, the flangeintegrally formed with the impingement panel segment.
 9. The impingementpanel as in claim 8, wherein an end plate is fixedly coupled to thesecond end of at least one impingement panel segment of the plurality ofimpingement panel segments, and wherein the end plate couples the secondend of the at least one impingement panel segment to a respective flangeof a neighboring impingement panel segment.
 10. An integrated combustornozzle comprising: a combustion liner extending along a radial directionbetween an inner liner segment and an outer liner segment, thecombustion liner including a forward end portion, an aft end portion, afirst side wall, and a second side wall, the aft end portion of thecombustion liner defining a turbine nozzle; and an impingement panelcomprising: an impingement plate disposed along an exterior surface ofone of the inner liner segment or the outer liner segment, wherein theimpingement plate defines a plurality of impingement apertures thatdirect coolant in discrete jets towards the exterior surface of the oneof the inner liner segment or the outer liner segment; a collection ductspaced apart from the impingement plate and defining a collectionpassage; an inlet portion extending from the impingement plate to thecollection duct; and at least one support coupled to the impingementplate and at least one of the inlet portion and the collection duct. 11.The integrated combustor nozzle as in claim 10, wherein the at least onesupport extends between and is coupled to the inlet portion, thecollection duct, and the impingement plate.
 12. The integrated combustornozzle as in claim 10, wherein the at least one support extends from afirst end fixedly coupled to the impingement plate to a second endfixedly coupled to the collection duct.
 13. The integrated combustornozzle as in claim 12, wherein the at least one support includes a firstside and a second side that extend between the first end and the secondend, and wherein the first side is fixedly coupled to the inlet portion.14. The integrated combustor nozzle as in claim 13, wherein the secondside of the at least one support forms an angle with the impingementplate that is between about 10° and about 75°.
 15. The integratedcombustor nozzle as in claim 10, wherein the at least one support formsan angle with the inlet portion that is between about 10° and about 90°.16. The integrated combustor nozzle as in claim 10, wherein theimpingement panel comprises a plurality of impingement panel segmentscoupled together.
 17. The integrated combustor nozzle as in claim 16,wherein each impingement panel segment of the plurality of impingementpanel segments extends between a first end of the impingement panelsegment and a second end of the impingement panel segment, and whereinthe first end includes a flange that extends from the impingement plateof the impingement panel segment, the flange integrally formed with theimpingement panel segment.
 18. The integrated combustor nozzle as inclaim 17, wherein an end plate is fixedly coupled to the second end ofat least one impingement panel segment of the plurality of impingementpanel segments, and wherein the end plate couples the second end of theat least one impingement panel segment to a respective flange of aneighboring impingement panel segment.
 19. The integrated combustornozzle as in claim 18, wherein the flange is generally perpendicular tothe impingement plate.
 20. A method for fabricating an impingementpanel, comprising: (a) irradiating a layer of powder in a powder bed toform a fused region, the powder bed disposed on a build plate; (b)providing a subsequent layer of powder over the powder bed by passing arecoater arm over the powder bed from a first side of the powder bed;and (c) repeating steps (a) and (b) until the impingement panel isformed on the build plate, wherein the impingement panel comprises: animpingement plate defining a plurality of impingement apertures; acollection duct spaced apart from the impingement plate and defining acollection passage; an inlet portion extending from the impingementplate to the collection duct; and at least one support coupled to theimpingement plate and at least one of the inlet portion and thecollection duct.